Washable and dry-cleanable knit garments having a permanent pleat and methods of manufacturing the same

ABSTRACT

One aspect of the invention provides a washable and dry-cleanable knit garment having a permanent pleat. The washable and dry-cleanable knit garment includes: a cotton-polyester blend knit fabric comprising at least 50% cotton; fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; and at least one permanent pleat formed in the fabric-fusible assembly. Another aspect of the invention provides a method of manufacturing a washable and dry-cleanable knit garment having a permanent pleat. The method includes: providing a cotton-polyester blend knit fabric comprising at least 50% cotton; applying fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; forming one or more pleats in the fabric-fusible assembly; and activating the fusible with a heat press.

BACKGROUND OF THE INVENTION

Pleats are used in clothing to gather a wide piece of fabric to a narrower circumference (e.g., for aesthetic reasons). Although cotton is a popular fabric (e.g., due to comfort and flexibility), it has been historically believed that cotton fabrics cannot be pleated, particularly in a manner that is feasible for production and wear.

SUMMARY OF THE INVENTION

One aspect of the invention provides a washable and dry-cleanable knit garment having a permanent pleat. The washable and dry-cleanable knit garment includes: a cotton-polyester blend knit fabric comprising at least 50% cotton; fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; and at least one permanent pleat formed in the fabric-fusible assembly.

This aspect of the invention can have a variety of embodiments. The cotton-polyester blend knit fabric can include between 49% and 20% polyester. The cotton-polyester blend knit fabric can include between 40% and 30% polyester. The cotton-polyester blend knit fabric can further include spandex.

The permanent pleat can be reinforced with stitching.

Another aspect of the invention provides a method of manufacturing a washable and dry-cleanable knit garment having a permanent pleat. The method includes: providing a cotton-polyester blend knit fabric comprising at least 50% cotton; applying fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; forming one or more pleats in the fabric-fusible assembly; and activating the fusible with a heat press.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and desired objects of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawing figures wherein like reference characters denote corresponding parts throughout the several views.

FIGS. 1A-1C depict a washable and dry-cleanable knit fabric (e.g., cut-and-sew knit fabric) before (FIG. 1A) and after (FIGS. 1B and 1C) various pleats is formed, respectively, according to an embodiment of the invention.

FIG. 2 depicts a method 200 of manufacturing a washable and dry-cleanable knit garment having a permanent pleat according to an embodiment of the invention.

FIGS. 3A-3D are photographs of a shirt including permanent pleats according to an embodiment of the invention. FIG. 3A is a front view. FIG. 3B is a left view (the right view being a mirror image thereof). FIG. 3C is a back view. FIG. 3D is a top view. Applicant notes that the utilitarian inventions described herein can be arranged to produce an ornamental design for a garment such as a skirt, a shirt, and the like (e.g., with claims directed to the shirt as a whole, with claims directed a shirt having pleated sleeves or other features as shown and described, and intermediate claims, whether in photographs or line drawings).

FIGS. 4A-4C are photographs of embodiments of the invention.

DEFINITIONS

The instant invention is most clearly understood with reference to the following definitions.

As used herein, the singular form “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about.

As used in the specification and claims, the terms “comprises,” “comprising,” “containing,” “having,” and the like can have the meaning ascribed to them in U.S. patent law and can mean “includes,” “including,” and the like.

As used herein, “dry cleanable” refers to a garment that can be laundered using a solvent other than water without affecting the appearance of a permanent pleat.

As used herein, “knit” refers to a textile formed from inter-looping of yarns or inter-meshing of loops.

Unless specifically stated or obvious from context, the term “or,” as used herein, is understood to be inclusive.

As used herein, “pleat” refers to a fold formed by doubling fabric back upon itself.

Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, combination of numbers, or sub-range from the group consisting 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 (as well as fractions thereof unless the context clearly dictates otherwise).

As used herein, “washable” refers to a garment that can be laundered in a washing machine or by hand without affecting the appearance of a permanent pleat.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the invention provide washable and dry-cleanable knit garments having a permanent pleat and methods of manufacturing the same. Embodiments of the invention enable pleats in garments such as a T-shirt, which is unusual, and enable a relaxed feel with substantive and tailored design elements.

Washable and Dry-Cleanable Knit Garment Having a Permanent Pleat

Referring to FIGS. 1A-1C, washable and dry-cleanable knit garment 100 includes a cotton-polyester blend knit fabric 102 and fusible interfacing 104 fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly 106. At least one permanent pleat 108 is formed in the fabric-fusible assembly 106. The relative dimensions of the garment 100 may be exaggerated for ease of illustration and understanding and the permanent pleat 108 and the fabric-fusible assembly 106 may lie substantially flat or in-plane relative to each other.

The content of the cotton-polyester blend knit fabric 102 can be determined by testing and specified in terms of mass, e.g., by the manufacturer of the cotton-polyester blend knit fabric 102. In some embodiments, the cotton-polyester blend knit fabric 102 has a cotton content of at least 50%, at least 60%, at least 70%, and the like. Exemplary cotton-polyester blend knit fabrics include 50/50 and 65/35 cotton-polyester blends. In some embodiments, the balance of the cotton-polyester blend knit fabric 102 consists substantially or exclusively of polyester. In other embodiments, additional fibers can be added (e.g., spandex, rayon, and the like). For example, the cotton-polyester blend knit fabric 102 could be 52% cotton, 34% polyester, and 14% spandex.

In some embodiments, the cotton-polyester blend knit fabric 102 can have a minimum amount of polyester, e.g., 20%. In some embodiments, the cotton-polyester blend knit fabric 102 includes between 49% and 20% or between 40% and 30% polyester.

Fusible interfacing 104 can be a textile having a heat-activated adhesive on one side. Fusible interfacing 104 can be affixed to the cotton-polyester blend knit fabric 102 using heat and moderate pressure, e.g., with a hand iron, a heat press, and the like. For example, the fusible interfacing 104 can be affixed to the cotton-polyester blend knit fabric 102 to form the fabric-fusible assembly 106 before the pleat 108 is formed. The garment 100 (particularly the pleat 108 can then be heated. Exemplary fusible interfacing includes CX11 available from STC-QST of Los Angeles, Calif., which is sufficiently thin so as to be imperceptible by sight or touch.

The permanent pleat 108 can optionally be reinforced with stitching 110. In some embodiments, the pleat edge is also hemmed to prevent unravelling of the fabric-fusible assembly 106. The stitching can 110 can run the length of (e.g., parallel with) the permanent pleat 108 (e.g., a running or baste stitch) or can be at one or more ends.

The permanent pleat 108 can be three-ply as depicted in FIG. 1B (e.g., at the origin of a flared pleat such as the shoulder of a sleeve) or two-ply as depicted in FIG. 1C (e.g., at the end of a flared pleat such as the distal end of a sleeve).

Method for Manufacturing a Knit Garment Having a Permanent Pleat

Referring to FIG. 2 , a method 200 of manufacturing a washable and dry-cleanable knit garment having a permanent pleat includes providing a cotton-polyester blend knit fabric comprising at least 50% cotton (S202); applying fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly (S204); forming one or more pleats in the fabric-fusible assembly (S206); activating the fusible with a heat press (S208); and optionally reinforcing the pleat with one or more stitches (S210).

The applying step (S204) can include heating the fusible to activate the adhesive. In some embodiments, the cotton-polyester blend knit fabric 102 and the fusible interfacing 104 are block-fused together before a pattern for the garment to contain the pleat 108 is cut.

A variety of parameters can be utilized depending on particular combinations of cotton-polyester blend knit fabric 102 and fusible interfacing 104. In one embodiment, the fabric-fusible assembly 106 is heated for 10 seconds in a heat press set to 300° F. (˜150° C.). Suitable heat presses are available under the MPRESS® trademark from eNetShops, LLC of Fullerton, Calif. The pressure applied is generally dictated by the particular heat press. Without being bound by theory, Applicant believes that typical pressures on the order of about 40 pounds-force (˜180 N)

EQUIVALENTS

Although preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.

INCORPORATION BY REFERENCE

The entire contents of all patents, published patent applications, and other references cited herein are hereby expressly incorporated herein in their entireties by reference. 

1. A washable and dry-cleanable knit garment having a permanent pleat, the washable and dry-cleanable knit garment comprising: a cotton-polyester blend knit fabric comprising at least 50% cotton; fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; and at least one permanent pleat formed in the fabric-fusible assembly.
 2. The washable and dry-cleanable knit garment having a permanent pleat of claim 1, wherein the cotton-polyester blend knit fabric comprises between 49% and 20% polyester.
 3. The washable and dry-cleanable knit garment having a permanent pleat of claim 1, wherein the cotton-polyester blend knit fabric comprises between 40% and 30% polyester.
 4. The washable and dry-cleanable knit garment having a permanent pleat of claim 1, wherein the cotton-polyester blend knit fabric further comprises spandex.
 5. The washable and dry-cleanable knit garment having a permanent pleat of claim 1, wherein the permanent pleat is reinforced with stitching.
 6. A method of manufacturing a washable and dry-cleanable knit garment having a permanent pleat, the method comprising: providing a cotton-polyester blend knit fabric comprising at least 50% cotton; applying fusible interfacing fused to an interior surface of the cotton-polyester blend knit fabric to form a fabric-fusible assembly; forming one or more pleats in the fabric-fusible assembly; and activating the fusible with a heat press. 